Blow Mould Tool Design and Manufacturing Process for 1litre Pet Bottle

Blow Mould Tool Design and Manufacturing Process for 1litre Pet Bottle


The concepts of Blow molding is a process used to produce hollow objects from thermoplastic. The basic blow molding process has two fundamental phases. First, a parson (or a perform) of hot plastic resin in a somewhat tubular shape is created. Second, compressed air is used to expand the hot perform and press it against mould cavities. The pressure is held until the plastic cools. Blow molding process is used for which has thin wall sections.In this thesis, blow mould design is to be done for a bottle having 0.5mm thickness. This thickness cannot be filled in pressure injection molding. So blow molding is considered for pet bottle design. The mould is prepared by first modeling the part, extracting core & cavity and generating CNC program. Blow mould tool design is done in Pro/Engineer according to HASCO standards. A prototype of the pet bottle using blow mould design is also included.



A bottle is a rigid container with a neck that is narrower than the body and a “mouth.Bottles are often made of glass, clay, plastic, aluminum or other impervious materials, and typically used to store liquids such as water, milk, soft drinks, ink, chemicals and etc. A device applied in the bottling line to seal the mouth of a bottle is termed an external bottle cap,. The bottle has developed over millennia of use, with some of the earliest examples appearing in China, Phoenicia, Rome and Crete. Bottles are often recycled according to the SPI recycling code for the material. Some regions have a legally mandated deposit which is refunded after returning the bottle to the retailer.

Plastic Bottle
Plastic bottles range from very small sample bottles to large carboys. The plastic is strain oriented in the stretch blow molding manufacturing process.

Hollow Plastic Molds And Molding Type

Injection Molding
When it comes to Injection Molding, the melted plastic will be forced into special mold cavities. When they cool down, the mold is removed. In plastic injection molding, heated plastic and is fed into the mold, which forms into the part as it cools

Blow Molding
This process is pretty much comparable with injection molding but the only difference is that, in this case, heated liquid plastic vertically pours out of barrel-like pot into molten tubes., the vacuum part is created. Most bottles, tubes or containers are formed with this type of molding. Hot plastic resin is combined with a pressurized gas to fill and press the mold cavity, forming a hollow part.

Compression Molding
This process also deals with plastic mold processes, but it involves pressing of solid plastic slugs between highly hot mold halves. Thus the parts created air-cooled afterwards. This molding process can also result in “flash lines” of extra plastic, like with regular injection molding.

Film Insert Molding
This molding technique literally imbeds images underneath the exterior of molded parts. At this point, materials akin to film or fabric will be slotted into the mold. Then plastic will be injected.

Blow Mould Extraction
This process is cheaper and quicker than permanent or sand mould casting. Most of the automobile parts like fuel pump, carburetor bodies, Horn heater, wipers, brackets, steering wheels, hubs and crank cases are made with this process.

Core: The core which is the male portion of the mold forms the internal shape of the molding.

Cavity: The cavity which is the female portion of the mold, gives the molding its external form. core & cavity extraction in Pro/Engineer

  • File – new- manufacturing- core and cavity-OK
  • Import reference model and assemble by using Default option

Select parting surface option and create parting surface
Select mould volume option from menu manager – select done – select parting surface option – select split option then it separates the volume into two half’s.

blow moulding dies and punch
blow moulding dies and punch

Manufacturing Process
By designed the mould tool for air PET BOTTLE, with the parameters now we can manufacture the air PET BOTTLE according to the dimensions. The flow chart of the manufacturing process of the air PET BOTTLE is given below.

Raw material

Hot die steels are most commonly used mould tool materials. they have Excellent toughness, ductility and harden ability .Used for vary large dies especially in thickness greater than 200mm .Also used for hot and warm forging and in extrusion tooling such as intricate dies and also dummy block ,liners, etc.

In my project I have modeled a pet bottle in CATIAV5. The manufacturing process for pet bottle is stretch blow moulding. I have designed total die for the pet bottle under the guidance of expert. I have also prepared prototype for the bottle and the free form. To validate the strength of the bottle, structural analysis is done on two models of pet bottle by applying pressure in the bottle when soft drink is taken. For the both models the analyzed stress values are less than the permissible value. I conclude that this design of pet bottle withstands the pressures when soft drink is filled in the bottle. The pressure values are taken from standards of Coco – Cola Company. I have completed blow moulding die according to standards. The design is ready for production.

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Sachin Thorat

Sachin is a B-TECH graduate in Mechanical Engineering from a reputed Engineering college. Currently, he is working in the sheet metal industry as a designer. Additionally, he has interested in Product Design, Animation, and Project design. He also likes to write articles related to the mechanical engineering field and tries to motivate other mechanical engineering students by his innovative project ideas, design, models and videos.

One thought on “Blow Mould Tool Design and Manufacturing Process for 1litre Pet Bottle

  1. Hello Sir,

    I’m in glass container/bottle industry and doing glass bottle design in creo software (3D & 2D). However I’m Very much interested in how plastic bottle design? because of their complex shapes and sizes, I want to know their design thinking like software, commands, Any special tool, etc. that will be helpful while creating glass bottle design.

    I will be grateful to you help me in this case.

    Thanks & Regards,
    Onkar M.

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